基于模糊控制的冷凝器自动转台焊机的研制

Development of Automatic Swilunvel Turntable Welding Machine for Condenser Based on Fuzzy Control

摘要:

针对工业生产中平行流冷凝器接管焊接自动化程度低,生产效率低,质量不稳定等缺点,提出了以PLC为核心控制器的新型自动转台式火焰焊接系统;采用4工位转台的工作方式,各工位同步运行且衔接紧密;利用组态软件完成界面设计,人机交互简洁,操作方便;控制算法采用模糊控制,利用PLC,流量传感器和调节阀构成反馈单元,依靠实时流量信息来调整模糊逻辑系统参数,并通过在线计算得到的最佳控制参数对空气及燃气流量进行调节;实验结果表明模糊控制较常规的流量控制稳态误差小,稳定周期短;通过机器能力指数C_mk分析,流量控制满足系统设计要求;实际生产中运行稳定且可靠,焊接合格率达到99.5%。

关键词:冷凝器;转台;火焰钎焊;模糊控制

Abstract:

A new automatic turntable flame welding system based on PLC is put forward to solve the problems of low degree of automation, low production efficiency and poor flame stability in parallel flow condenser welding. Every station can run synchronously and link up tightly by a four-station turntable. Human-computer interaction is easy to operate by using the configuration software to complete the system interface design. Control algorithm uses fuzzy control. System uses PLC, flow sensor and regulator to form a feedback unit and rely on real-time flow information to adjust the parameters of the fuzzy logic system. Besides, system adjusts air and gas flow through optimal control parameters calculating online. The experimental results show that comparing with conventional control, fuzzy control has smaller steady state error, shorter stable cycle. Through the analysis of the machine capability index C_mk, the flow control precision meets industry requirement. The system is stable and reliable in actual production and the welding qualification rate reaches 99.5%.

Key words:condenser; turntable; flame brazing; fuzzy control